JP6991375B1 - Machine Tools - Google Patents

Abstract

PROBLEM TO BE SOLVED: To secure the contrast of a captured image regardless of the tool length and to detect the shape of a tool with sufficient accuracy. A tool accommodating device accommodates a plurality of tool Tx. The tool accommodating device includes an image pickup unit 50 that captures an image of the tool Tx, a tool transfer unit that conveys the tool Tx, an illumination unit 52 that illuminates the tool Tx, and a moving mechanism 54 for moving the illumination unit 52. The illumination unit 52 is moved in the longitudinal direction of the tool Tx, and the tool Tx is imaged. [Selection diagram] Fig. 3

Description

The present invention relates to a tool inspection technique in a machine tool.

Machine tools include a turning center that moves a tool with respect to a rotating work, a machining center that moves a rotating tool with respect to the work, and a multi-tasking machine having these functions in combination. The machine tool is equipped with a tool changing device called ATC (Automatic Tool Changer), and the work is machined into a desired shape while exchanging a plurality of types of tools in the machining process. The ATC performs tool exchange between the tool accommodating portion (magazine or the like) and the tool holding portion (spindle or the like).

In such a machine tool, if the tool after use has an abnormality such as a defect, breakage, or wrapping of chips, the tool (hereinafter, also referred to as "defective tool") cannot be used as it is for the next machining. Therefore, a technique has been proposed in which the blade shape is imaged by a camera before and after the use of the tool, and whether or not the tool is defective is determined based on the captured images before and after the use of the tool (Patent Document 1).

In the tool inspection, for example, lighting is applied from one side of the tool, and the camera is imaged by a camera installed on the other side. The silhouette of the tool is projected by using the transmitted lighting, and the contour of the tool is specified based on the silhouette. If a normal contour shape cannot be obtained, it can be determined that the tool is defective.

Japanese Unexamined Patent Publication No. 2015-131357

The accuracy of such tool inspection depends on the contrast of the captured image. It is necessary to obtain a good silhouette of the tool, and for this purpose, the image target portion of the tool (for example, from the cutting edge to the cutting edge) must be uniformly illuminated. However, since the dimensions of the tools accommodated in the tool accommodating portion vary, if the tools are too large for the illumination range, uniform illumination becomes difficult. On the other hand, it is disadvantageous in terms of cost to adopt a large lighting device for a large tool.

One aspect of the present invention is a tool accommodating device for accommodating a plurality of tools. This tool accommodating device includes an image pickup unit that captures an image of the tool, a tool transport unit that conveys the tool, an illumination unit that illuminates the tool, and a moving mechanism for moving the illumination unit, and illuminates in the longitudinal direction of the tool. Move the part and take an image of the tool.

Another aspect of the invention is a machine tool. This machine tool includes the above-mentioned tool accommodating device, a processing device for processing a work using the tools accommodated in the tool accommodating device, and an opening / closing mechanism for opening and closing an opening provided in a partition wall between the tool accommodating device and the processing device. , Equipped with. The tool transfer unit includes a tool exchange unit that performs tool exchange between the tool accommodating device and the machining device with the opening open. The image of the tool is taken by the tool accommodating device.

According to the present invention, the contrast of the captured image can be ensured regardless of the tool length, and the shape of the tool can be detected with sufficient accuracy.

It is a perspective view which shows the appearance of the machine tool which concerns on embodiment. It is a side view which shows the internal structure of a tool accommodating device. It is a perspective view which shows the structure of a containment chamber schematically. It is a front view schematically showing the periphery of the boundary part between a containment chamber and a processing chamber. It is a hardware block diagram of a machine tool and an image processing apparatus. It is a functional block diagram of an image processing apparatus. It is a figure which shows the imaging method of the target tool. It is a flowchart which shows the processing process of the tool shape data acquisition process before use. It is a flowchart which shows the process process of a tool inspection process. It is a figure which shows the image pickup method of the target tool which concerns on modification 1. FIG. It is a figure which shows typically the relationship between the angle of view of a camera and a partial image when a tool is long. It is a perspective view which shows typically the structure of the accommodation chamber which concerns on modification 2. FIG.

Hereinafter, an embodiment of the present invention will be described with reference to the drawings. The machine tool of the present embodiment is configured as a machining center for machining a work into a desired shape while appropriately exchanging tools.

FIG. 1 is a perspective view showing the appearance of the machine tool according to the embodiment. When the machine tool 1 is viewed from the front, the front-rear direction, the left-right direction, and the up-down direction are the Z-axis direction, the X-axis direction, and the Y-axis direction, respectively.
The machine tool 1 includes a processing device 2 and a tool accommodating device 4. A cover 6 (device housing) is provided so as to cover these devices. Inside the cover 6, a processing chamber 8 is provided on the right side when viewed from the front, and a storage chamber 10 is provided on the left side. Machining is performed by the processing apparatus 2 in the processing chamber 8. In the storage chamber 10, a plurality of tools are stored by the tool storage device 4, and tools are exchanged by ATC (details will be described later).

An operation panel 12 is provided on the right side surface of the cover 6. An image processing device 14 is connected to the processing chamber 8. The user can remotely monitor the work status of the machine tool 1 by the image processing device 14. The image processing device 14 may be a general laptop PC (Personal Computer) or a tablet computer. In the modified example, the image processing device may be configured as an internal device of the processing chamber 8.

FIG. 2 is a side view showing the internal configuration of the tool accommodating device 4. This figure corresponds to the left side view of the machine tool 1, but for convenience of explanation, the left side surface of the cover 6 is removed. In addition, a part of the magazine (described later) is partially cut out and displayed.

The tool accommodating device 4 has a disk-type magazine 20. A plurality of pots 22 are arranged along the outer peripheral surface of the magazine 20, and each of them is configured to be able to store the tool T. Each pot 22 coaxially supports the tool T, and a plurality of tools are radially supported around the rotation shaft 24 of the magazine 20. In the modified example, a chain type or other magazine may be adopted.

The magazine 20 rotates about a rotation shaft 24 and horizontally supports the tool T to be replaced at its front end position (right end position in FIG. 2). That is, the pot 22 of the magazine 20 functions as a "tool support portion" that supports the tool T (also referred to as "target tool Tx") to be replaced in the storage chamber 10 in a standby state.

An opening 28 is provided in the partition wall 26 that separates the storage chamber 10 and the processing chamber 8, and a shutter 30 for opening and closing the opening 28 is arranged. The shutter 30 and its drive mechanism 32 function as an "opening / closing mechanism" for opening / closing the opening 28. ATC34 is provided in the accommodation chamber 10. The ATC 34 includes a tool T (also referred to as “pre-use tool Tp”) held in the accommodation chamber 10 in a standby state and a tool T (“used”) held by the tool spindle (not shown) in the machining chamber 8. Replace with "Tool Tu"). The tool change is performed with the shutter 30 open.

The target tool Tx is horizontally supported as a replacement target in the storage chamber 10. The target tool Tx includes a pre-use tool Tp immediately before the tool change and a used tool Tu immediately after the tool change. In this embodiment, an image of the pre-use tool Tp and an image of the used tool Tu are taken for the same tool. Based on the comparison between the image of the pre-use tool Tp and the image of the used tool Tu, the state of the used tool Tu (whether or not it is a defective tool, etc.) is determined. The details will be described later.

FIG. 3 is a perspective view schematically showing the configuration inside the accommodation chamber 10. FIG. 4 is a front view schematically showing the periphery of the boundary between the accommodation chamber 10 and the processing chamber 8.
As shown in FIG. 3, the target tool Tx is horizontally supported in the accommodation chamber 10. The shutter 30 is driven in parallel with the target tool Tx by a drive mechanism (for example, a screw feed mechanism) (not shown) to open and close the opening 28.

As shown in FIG. 4, the ATC 34 is arranged in the space between the target tool Tx and the shutter 30. The ATC 34 includes a main body 36 containing a motor and an arm 38 attached to a rotating shaft of the motor. The arm 38 has a shape symmetrical with respect to the rotation axis, and has grip portions 40 at both ends thereof. The grip portion 40 includes a fixed claw 42 and a movable claw 44. By driving the movable claw 44, the gripping operation by the gripping portion 40 can be realized.

The ATC 34 is provided with a translation mechanism for moving the arm 38 in the axial direction and a rotation mechanism for rotating the arm 38 around the axis. The motor includes a first motor that drives the translational mechanism and a second motor that drives the rotation mechanism. Since such a mechanism itself is known, a detailed description thereof will be omitted.

When the ATC 34 is not activated, the arm 38 is in a state of being vertically oriented as shown in FIG. As a result, the ATC 34 is accommodated in the accommodation chamber 10 with the shutter 30 closed. When the ATC 34 is operated, the pre-use tool Tp stands by on one side (accommodation chamber 10 side) and the used tool Tu stands by on the other side (machining chamber 8 side) across the axis of the arm 38. At this time, the shutter 30 is released.

When the ATC 34 operates, the arm 38 rotates so that the pair of gripping portions 40 grip the pre-use tool Tp and the used tool Tu, respectively. At this time, the arm 38 temporarily straddles the opening 28. Further, by driving the translation mechanism and the rotation mechanism, the tool is detached and attached to the pot 22 and the tool spindle 35, and the tool can be replaced. Since the operation of such an ATC itself is known, a detailed description thereof will be omitted.

The lighting device 52 is arranged above the holding position of the target tool Tx, and the camera 50 is arranged below. The camera 50 includes an image sensor (image sensor) such as a CMOS (Complementary Metal Oxide Semiconductor) or a CCD (Charge-Coupled Device). The camera 50 in this embodiment has a resolution of about 1 million pixels (1224 × 1024) of the tool information storage unit. Further, the camera 50 can acquire up to 80 captured images per second.

The lighting device 52 functions as a “lighting unit” and illuminates the target tool Tx from above. The camera 50 functions as an "imaging unit" and images the target tool Tx from below. In this way, the camera 50 and the lighting device 52 are arranged on the opposite side of the target tool Tx. Due to the transmitted illumination by the illuminating device 52, the camera 50 can acquire a high-contrast captured image in which the contour position of the tool T can be easily grasped.

Returning to FIG. 3, a moving mechanism 54 for moving the lighting device 52 in the longitudinal direction of the target tool Tx is provided above the target tool Tx. The moving mechanism 54 includes a guide rail 56 and an air cylinder 58. The guide rail 56 extends parallel to the axis of the target tool Tx, and the lighting device 52 is slidably attached. The lighting device 52 is fixed to the tip of the rod of the air cylinder 58. The air cylinder 58 reciprocates the lighting device 52 along the guide rail 56.

As shown in FIG. 4, the extension direction of the guide rail 56 is parallel to the longitudinal direction of the target tool Tx at the tool change standby position. Further, the extension direction of the guide rail 56 is parallel to the rotation axis Lx of the ATC 34. The extension direction of the guide rail 56, the longitudinal direction of the target tool Tx at the tool change standby position, and the rotation axis Lx of the ATC 34 are all designed to be parallel to the Z axis.

The camera 50 takes an image of the target tool Tx from below (Y-axis direction). The distance between the camera 50 and the target tool Tx (working distance: hereinafter also referred to as “WD”) is set so that the image pickup target portion of the target tool Tx can be accommodated on one screen (see FIG. 4). The "imaging target portion" means a portion (also referred to as an "inspection target portion") that requires inspection to determine whether or not the target tool Tx is a defective tool, and is set in advance. In the present embodiment, the image pickup target portion is from the base end supported by the pot 22 to the cutting edge in the target tool Tx. In the modified example, the image pickup target portion may be from the blade edge to the blade edge.

In the present embodiment, the shutter 30 moves in the opening direction after taking an image while the lighting device 52 moves a plurality of times, and the tool is exchanged. In the modified example, the lighting device 52 may start moving after the first imaging at the standby position (position shown in FIG. 3). The shutter 30 may start moving in the opening direction before the camera 50 takes a second image. The shutter 30 may be moved when the lighting device 52 stops moving and takes a second image.

In another modification, the lighting device 52 may start moving after the first imaging at the standby position (position shown in FIG. 3). The shutter 30 may start moving in the opening direction before the camera 50 takes a second image. Then, when the lighting device 52 stops moving and the second image is taken, the shutter 30 may also be temporarily stopped.

Although not shown in FIGS. 3 and 4, each structure such as the main body 36 of the ATC 34, the guide rail 56, the air cylinder 58, and the lighting device 52 is formed on a wall surface, a beam, or the like in the accommodation chamber 10. Needless to say, it is fixed stably.

FIG. 5 is a hardware configuration diagram of the machine tool 1 and the image processing device 14.
The machine tool 1 includes the above-mentioned machining device 2, the tool accommodating device 4, and the ATC 34, as well as the machining control device 60 and the operation control device 62. The machining control device 60 functions as a numerical control device and outputs a control signal to the machining device 2 according to the machining program. The machining device 2 drives a tool spindle (not shown) according to an instruction from the machining control device 60 to machine a workpiece.

The operation control device 62 includes an operation panel 12 and controls the machining control device 60. The ATC 34 takes out the tool from the tool accommodating device 4 according to the exchange instruction from the machining control device 60, and exchanges the used tool Tu held on the tool spindle with the pre-use tool Tp taken out from the tool accommodating device 4.

The image processing device 14 mainly performs image processing such as tool shape recognition. As described above, the image processing device 14 may be configured as a part of the operation control device 62. Alternatively, the entire body including the image processing device 14 may be referred to as "machine tool 1".

FIG. 6 is a functional block diagram of the image processing device 14.
Each component of the image processing device 14 includes a CPU (Central Processing Unit), a computing unit such as various auxiliary processors, a storage device such as a memory and a storage device, hardware including a wired or wireless communication line connecting them, and a storage device. It is stored in and realized by software that supplies processing instructions to the arithmetic unit. The computer program may be composed of a device driver, an operating system, various application programs located on the upper layer thereof, and a library that provides common functions to these programs. Each block described below shows a block for each function, not a configuration for each hardware.

The operation control device 62 and the processing control device 60 are also stored in a computing device such as a processor, a storage device such as a memory and a storage device, hardware including a wired or wireless communication line connecting them, and a computing device. The software or program that supplies the processing instructions may be realized on an operating system separate from the image processing device 14.

The image processing device 14 includes a user interface processing unit 70, a data processing unit 72, a data storage unit 74, and a communication unit 76.
The user interface processing unit 70 accepts operations from the user and is in charge of processing related to the user interface such as image display and audio output. The communication unit 76 is in charge of communication with the operation control device 62. The data processing unit 72 executes various processes based on the data acquired by the user interface processing unit 70 and the data stored in the data storage unit 74. The data processing unit 72 also functions as an interface for the user interface processing unit 70, the data storage unit 74, and the communication unit 76. The data storage unit 74 stores various programs and setting data.

The user interface processing unit 70 includes an input unit 80 and an output unit 82.
The input unit 80 receives input from the user via a hard device such as a touch panel or a handle. The output unit 82 provides various information to the user via an image display or an audio output. The output unit 82 includes a notification unit 84. The notification unit 84 notifies the user of the occurrence of various events when a predetermined abnormality condition such as an abnormality of the tool to be replaced (a defective tool is detected) is satisfied (details will be described later).

The communication unit 76 includes a reception unit 110 that receives data from the operation control device 62, and a transmission unit 112 that transmits data and commands to the operation control device 62.

The data processing unit 72 includes a movement control unit 90, an image pickup processing unit 92, a shape reproduction unit 94, a tool management unit 96, and a determination processing unit 98.
The movement control unit 90 drives and controls the movement mechanism 54 to control the movement of the lighting device 52. The image pickup processing unit 92 controls the camera 50 to take an image of the target tool Tx. The shape reproduction unit 94 generates "tool shape data" which is data indicating the shape of the target tool Tx based on the captured image. The tool management unit 96 associates the tool ID and the tool shape data for each target tool Tx and registers them in the data storage unit 74.

The determination processing unit 98 determines whether or not the target tool Tx has an abnormality such as a defect, breakage, or wrapping of chips based on the captured image of the target tool Tx or based on the tool shape data (whether or not the tool is defective). Or) is determined. When the determination processing unit 98 determines that the target tool Tx is abnormal, the notification unit 84 notifies the user to that effect. The determination processing unit 98 may instruct the operation control device 62 to display the fact on the operation panel 12. When it is determined that the used tool Tu is a defective tool, the tool management unit 96 associates the information that the used tool Tu is with the tool ID and registers it in the data storage unit 74 as the tool information.

The data storage unit 74 includes a tool information storage unit 100 and a shape data storage unit 102. The tool information storage unit 100 stores information (tool information) of each tool T stored in the magazine 20 in association with the tool ID. The tool information includes, for example, information such as the type, shape, size, and length of the tool. Further, information such as cumulative usage time and cumulative usage count may be included. The data storage unit 74 also temporarily stores the captured image.

The tool information storage unit 100 updates the tool information every time the tool is replaced. If it is determined that the target tool Tx is a defective tool as described above, that fact is added as tool information. After the determination, the tool management unit 96 prohibits the use of the tool T on the defective tool, that is, the tool replacement as the pre-use tool Tp by the ATC34.

The shape data storage unit 102 stores the tool shape data generated by the shape reproduction unit 94 in association with the tool ID. In this embodiment, tool shape data is created before and after tool replacement. Therefore, for each target tool Tx, the tool shape data of the pre-use tool Tp (hereinafter also referred to as “pre-use tool shape data”) and the tool shape data of the used tool Tu (hereinafter also referred to as “used tool shape data”). ) Is stored in association with the tool ID. The determination processing unit 98 can determine whether or not the used tool Tu is a defective tool by comparing the pre-use tool shape data and the used tool shape data for the same tool.

Next, a method of imaging the tool will be described.
FIG. 7 is a diagram showing a lighting method of the target tool Tx at the time of imaging. FIG. 7A shows a state before the movement of the lighting device 52, and FIG. 7B shows a state after the movement of the lighting device 52. The upper part of each figure shows a side view, and the lower part shows a plan view. The two-dot chain line in the figure indicates a region where the contrast of the captured image is good due to illumination (that is, a region where the illumination is good for imaging: hereinafter also referred to as “recommended imaging region S”).

In this embodiment, a lighting device 52 having a predetermined size is used. On the other hand, as described above, in the target tool Tx, the area from the base end supported by the pot 22 to the cutting edge is the image pickup target portion Ta. Therefore, as shown in FIG. 7A, when the target tool Tx becomes large to some extent, the image pickup target portion Ta cannot be contained in the image pickup recommended region S, and an image having high contrast is obtained over the entire image pickup target portion Ta. I can't. Therefore, it is conceivable to use a larger lighting device 52, but as already mentioned, this leads to an increase in cost.

Therefore, in the present embodiment, a method is adopted in which the lighting device 52 is moved by the moving mechanism 54, the target tool Tx is imaged a plurality of times, and the shape of the entire image pickup target portion Ta is recognized based on the plurality of captured images. Hereinafter, a part of the area in each of the plurality of captured images, that is, a part of the image of the target tool Tx is referred to as a “partial image”. When the lighting device 52 is moved, the image pickup processing unit 92 captures an image of the target tool Tx a plurality of times before and after the movement and at least one of the movement processes, and acquires a plurality of captured images.

Specifically, an image is taken at the operation starting point of the moving mechanism 54 (FIG. 7 (A)), and further, an image is taken at the operating intermediate point or the operating end point of the moving mechanism 54 (FIG. 7 (B)). The "operation start point" here corresponds to the contracted state of the air cylinder 58, and the "operation intermediate point" and the "operation end point" correspond to the extended state of the air cylinder 58. The "operation intermediate point" may be a temporary stop point of the lighting device 52 or a moving passing point. It is preferable to set it as a pause point in order to acquire an image with less noise due to a change in lighting. The "operation end point" is the movement limit point of the lighting device 52 (corresponding to the extension limit of the air cylinder 58). By narrowing the exposure time of the camera 50, the lighting device 52 may be imaged without pausing at the operation intermediate point.

In the example of FIG. 7, the image is taken once at the operation starting point of the moving mechanism 54 (FIG. 7 (A)) and once again at the operating end point of the moving mechanism 54 (FIG. 7 (B)). Of the two captured images acquired at this time, a part of the first image (the portion closer to the proximal end side of the image pickup target portion Ta) is the partial image P1, and a part of the second image (the image capture target portion Ta). The portion closer to the tip side of the image P2. Each partial image corresponds to the recommended imaging region S. Since the amount of movement of the lighting device 52 between the front and back imaging is smaller than the length of the recommended imaging region S, the partial image P1 and the partial image P2 partially overlap (see the overlapping portion L: broken line region).

The image pickup processing unit 92 acquires the entire image of the image pickup target portion Ta by connecting the partial image P1 and the partial image P2 so as to overlap the overlapping portions L. As the overlap portion L, one of the partial image P1 and the partial image P2 (for example, the one having the higher contrast) may be adopted. The image pickup processing unit 92 specifies the contour of the target tool Tx (image pickup target unit Ta) based on the plurality of partial images P1 and P2.

Specifically, the silhouette of the target tool Tx projected by the lighting device 52 is displayed as the entire image of the image pickup target portion Ta. The image pickup processing unit 92 sets a scanning line in the X-axis direction, and sets a point located at the boundary from a dark region (silhouette region where the target tool Tx exists) to a bright region (region where the target tool Tx does not exist) as an edge point. To detect. The image pickup processing unit 92 detects a plurality of edge points while shifting the scanning lines at a constant pitch, and identifies the contour of the target tool Tx by connecting these edge points. The shape reproduction unit 94 generates tool shape data based on the specified contour.

The determination processing unit 98 compares the pre-use tool shape data and the used tool shape data for the same tool. In the determination processing unit 98, when the similarity between the shape of the tool before use and the shape of the used tool, particularly the similarity of the contour is equal to or less than a predetermined value, the target tool Tx has a defect or the like, that is, the target tool. It is determined that Tx is a defective tool. At this time, the notification unit 84 causes the user to display an alert screen indicating that a defective tool has been detected. Alternatively, a sound such as a buzzer sound may be generated.

FIG. 8 is a flowchart showing the processing process of the pre-use tool shape data acquisition process.
This process is executed when the pre-use tool Tp is held horizontally in the storage chamber 10 in the standby state prior to the tool change. At this time, the moving mechanism 54 is inactive, and the lighting device 52 is in the standby position (reference position).

The image pickup processing unit 92 takes an image of the pre-use tool Tp with the camera 50, and acquires a partial image P1 corresponding to the image pickup recommended area S (S10). Subsequently, the movement control unit 90 operates the movement mechanism 54 to move the lighting device 52 to the next lighting position (S12). In the present embodiment, since the air cylinder 58 is adopted as the moving mechanism 54, the lighting device 52 moves to the moving limit point and stops without being temporarily stopped. The image pickup processing unit 92 takes an image of the pre-use tool Tp and acquires a partial image P2 corresponding to the image pickup recommended area S (S14).

After the partial images P1 and P2 are acquired in this way, the movement control unit 90 operates the movement mechanism 54 to return the lighting device 52 to the standby position (S16). The shape reproduction unit 94 generates pre-use tool shape data based on the partial images P1 and P2 (S18). The tool management unit 96 stores the pre-use tool shape data in the shape data storage unit 102 in association with the tool ID (S20). This pre-use tool shape data is used for tool inspection described later. The pre-use tool shape data may be created in parallel in the process of the lighting device 52 moving toward the standby position.

FIG. 9 is a flowchart showing the processing process of the tool inspection process.
This process is executed when the used tool Tu is held horizontally in the storage chamber 10 in the standby state prior to the tool storage after the tool change. At this time, the moving mechanism 54 is inactive, and the lighting device 52 is in the standby position (reference position).

The image pickup processing unit 92 takes an image of the used tool Tu by the camera 50, and acquires a partial image P1 corresponding to the image pickup recommended area S (S30). Subsequently, the movement control unit 90 moves the lighting device 52 to the next lighting position (S32). The image pickup processing unit 92 takes an image of the used tool Tu and acquires a partial image P2 corresponding to the image pickup recommended area S (S34). After that, the movement control unit 90 returns the lighting device 52 to the standby position (S36).

On the other hand, the shape reproduction unit 94 generates used tool shape data based on the partial images P1 and P2 (S38). The tool management unit 96 temporarily stores the used tool shape data in the shape data storage unit 102 (S40). The determination processing unit 98 reads out the used tool shape data and the pre-use tool shape data having the same tool ID, and compares the tool shape data (S44). That is, the shape of the tool before use and the shape of the used tool are compared for the same tool. At this time, if the degree of similarity between the used tool shape and the pre-use tool shape is a defective tool of a predetermined value or less (Y in S46), the notification unit 84 is notified to that effect (S48). That is, the notification unit 84 displays the alert screen. If it is not a defective tool (N of S46), the process of S48 is skipped.

In the present embodiment, the used tool Tu, which is determined to be a defective tool after the tool is replaced, is also stored in the magazine 20, but the tool is prohibited from being used until the predetermined maintenance is performed. The information that the tool is prohibited is stored in association with the tool ID.

In general, a tool has an upper limit of the number of times of use and the time of use (also referred to as "quality assurance parameter") in order to ensure its quality. Tools whose quality assurance parameters exceed the upper limit are prohibited from use, and tools of the same type (sub-tools) prepared separately and stored in the magazine 20 are used. As a result, the mass production process by the processing apparatus 2 is not hindered. In the present embodiment, even if the quality assurance parameter does not exceed the upper limit value, when a defective tool is detected, the sub tool is used while managing the corresponding tool as prohibition of use.

The machine tool 1 has been described above based on the embodiment.
In the present embodiment, the tool accommodating device 4 is provided with the lighting device 52 and the moving mechanism 54, and the lighting device 52 is moved in the longitudinal direction of the target tool Tx to perform multiple imaging. Therefore, it is not necessary to adopt a large and expensive lighting device 52. That is, according to the present embodiment, it is possible to secure the contrast of the captured image regardless of the tool length while suppressing the cost, and it is possible to detect the shape of the tool with sufficient accuracy.
[Modification example]
FIG. 10 is a diagram showing an image pickup method of the target tool Tx according to the first modification. FIG. 10A shows an imaging method when the target tool Tx is short, and FIG. 10B shows an imaging method when the target tool Tx is longer.

In the above embodiment, a configuration is exemplified in which a high-contrast overall image is acquired by imaging and synthesizing the image pickup target portion Ta of the target tool Tx twice. That is, the lighting device 52 was moved regardless of the length of the target tool Tx, and the number of times of imaging by the camera 50 was set to a plurality of times. Therefore, when the target tool Tx is short, there is a possibility that the image pickup will be missed. In this modification, the number of imagings is appropriately changed according to the length of the target tool Tx.

That is, as the image pickup mode by the camera 50, the image pickup processing unit 92 has a first image pickup mode in which one target tool Tx is imaged a plurality of times and a second image pickup mode in which one target tool Tx is imaged only once. Includes modes. The image pickup processing unit 92 acquires the information of the target tool Tx from the tool information storage unit 100, and selects either the first image pickup mode or the second image pickup mode based on the information of the target tool Tx.

As shown in FIG. 10A, when the image pickup target portion Ta is short enough to fit in the image pickup recommended area S, the lighting device 52 is prevented from moving. The tool length information is stored in the tool information storage unit 100 in association with the tool ID. The movement control unit 90 reads out the tool information corresponding to the target tool Tx, and prevents the movement mechanism 54 from operating when the tool length is equal to or less than the first reference value. The "first reference value" may be the length of the recommended imaging region S, or may be shorter than that (see FIG. 7).

On the contrary, as shown in FIG. 10B, if there is a portion of the imaging target portion Ta that cannot be contained in the recommended imaging region S in any of the two imagings, the number of imagings is set to 3 or more. When the length of the target tool Tx exceeds the second reference value, the movement control unit 90 intermittently operates the movement mechanism 54 a plurality of times. The image pickup processing unit 92 takes an image of the target tool Tx every time the movement of the lighting device 52 is stopped. The "second reference value" and the "number of times of imaging" may be set based on the length of the recommended imaging region S. The length of the guide rail 56 is set based on the maximum length of the tool T stored in the magazine 20.

FIG. 11 is a diagram schematically showing the relationship between the angle of view of the camera and the partial image when the tool is long. 11 (A) is a side view, and FIG. 11 (B) is a plan view. The alternate long and short dash line in the figure indicates a region that falls within the angle of view of the camera 50. The example of this figure corresponds to the case of FIG. 10B.

As shown in FIG. 11A, the camera 50 has an angle of view sufficient to accommodate the image pickup target portion Ta of the target tool Tx in the image pickup region. As shown in FIG. 11B, in the first image pickup in which the lighting device 52 is in the standby position, the image pickup recommended area S corresponds to a part of the image pickup image Pa (overall image). A part of the captured image Pa is acquired as a partial image P1. In the second and third imaging, the recommended imaging region S shifts to the right side in the figure, so that the partial image is also acquired so as to shift to the right side portion of the captured image Pa.

As shown in FIG. 10B, when the lighting device 52 is intermittently stopped for image pickup, it is difficult to perform highly accurate positioning control with the air cylinder 58. Therefore, for example, a screw feed mechanism and a servomotor for driving the screw feed mechanism may be adopted as the movement mechanism. Alternatively, a linear drive device including a linear motor may be adopted. These screw feed mechanisms and linear drive devices function as "feed devices" that reciprocate the lighting device 52 in the linear direction. Of course, also in the above embodiment, a feeding device may be adopted instead of the air cylinder 58.

FIG. 12 is a perspective view schematically showing the configuration inside the accommodation chamber 10 according to the modified example 2.
In the above embodiment, a configuration in which the lighting unit (lighting device 52) is moved has been exemplified. In this modification, the image pickup unit (camera 50) is also moved in parallel with the target tool Tx. That is, a moving mechanism 154 for moving the camera 50 in the longitudinal direction of the target tool Tx is provided below the target tool Tx in the accommodation chamber 10. The moving mechanism 154 includes a guide rail 156 and an air cylinder 158. The guide rail 156 extends parallel to the axis of the target tool Tx, and the camera 50 is slidably attached. The camera 50 is fixed to the tip of the rod of the air cylinder 158. The air cylinder 158 reciprocates the camera 50 along the guide rail 156.

The movement control unit 90 controls the movement mechanisms 54 and 154 to move the lighting device 52 and the camera 50 in parallel with the target tool Tx while facing each other in the vertical direction. With such a configuration, it is possible to acquire an image with high contrast over the entire image target portion Ta. Also in this modification, a screw feed mechanism or a linear drive device may be adopted instead of the air cylinder 158.

The present invention is not limited to the above-described embodiment or modification, and the components can be modified and embodied within a range that does not deviate from the gist. Various inventions may be formed by appropriately combining a plurality of components disclosed in the above-described embodiments and modifications. In addition, some components may be deleted from all the components shown in the above embodiments and modifications.

In the above embodiment, the configuration in which the determination processing unit 98 determines whether or not the target tool Tx is a defective tool is exemplified. In the modification, the tool shape data generated by the shape reproduction unit 94 for the pre-use tool Tp and the used tool Tu may be drawn and displayed in comparison with the output unit 82. The user may visually compare the tool shapes before and after use to determine whether or not the target tool Tx is a defective tool.

In the above embodiment, each target tool Tx is imaged before and after tool replacement (that is, before and after machining), and tool shape data is generated. Then, by comparing the pre-use tool shape data and the used tool shape data for each tool, it was determined whether or not there was an abnormality such as a defect. In the modification, the defective tool may be determined by using the tool image itself without generating the tool shape data (tool contour data). That is, it may be determined whether or not the used tool Tu is a defective tool by comparing the pre-use tool image and the used tool image for each target tool Tx.

In the above embodiment, each target tool Tx is imaged immediately before and after machining, and the state of the used tool Tu (whether or not it is a defective tool) is determined based on those images. That is, an example is shown in which the captured image immediately before use is used as a judgment criterion as a "reference image". In the modified example, the reference image may be stored as basic data at the time of tool registration before the start of the first use of the tool. However, in order to perform more accurate shape detection (shape comparison) by making the imaging environment such as the lighting state the same, it is preferable to compare the image immediately before machining with the image immediately after machining.

In the above embodiment, an example is shown in which the imaging unit (camera 50) is arranged below the target tool Tx and the lighting unit (illuminating device 52) is arranged above the target tool Tx. On the contrary, in the modified example, the image pickup unit may be arranged above the target tool Tx, and the illumination unit may be arranged below the target tool Tx. From the viewpoint of preventing contamination of the camera lens, the arrangement of this modification is preferable. This is because if the camera is placed below the target tool, for example, if the target tool is a used tool, coolant may drip from the used tool and contaminate the camera lens. According to the variant, there is no such concern. In that case, the moving mechanism may also be arranged below the target tool.

In the above embodiment, the ATC 34 is exemplified as the "tool transport unit", but a tool transport mechanism for transporting tools between the machining chamber and the accommodating chamber may be provided without having a tool changing function.

In the above embodiment, the machining center is exemplified as the machine tool 1, but it goes without saying that the inspection technique of the tool can be applied to the turning center and the multi-tasking machine.

1 Machinery, 2 Machining equipment, 4 Tool accommodating equipment, 6 covers, 8 Machining chambers, 10 accommodating chambers, 12 operation panel, 14 image processing equipment, 20 magazines, 22 pots, 26 partition walls, 30 shutters, 32 drive mechanisms, 34 ATC, 38 arm, 50 camera, 52 lighting device, 54 movement mechanism, 56 guide rail, 58 air cylinder, 60 processing control device, 62 operation control device, 90 movement control unit, 92 image processing unit, 94 shape reproduction unit, 96 Tool management unit, 98 judgment processing unit, 100 tool information storage unit, 102 shape data storage unit, P1 partial image, P2 partial image, S imaging recommended area, T tool, Ta imaging target unit, Tp pre-use tool, Tu used Tools, Tx target tools.

Claims (6)

A processing device that processes workpieces using tools, and
A tool accommodating device including a tool changing unit that performs tool exchange with the processing device, a lighting unit that illuminates the tool, a moving mechanism that moves the lighting unit, and an image pickup unit that captures an image of the tool.
An opening / closing mechanism for opening / closing an opening provided in a partition wall between the tool accommodating device and the processing device,
Equipped with
The moving mechanism moves the lighting unit in the longitudinal direction of the tool and in the direction of the rotation axis of the tool changing unit when the tool is within the operating range of the tool changing unit.
When the tool is within the operating range of the tool changer, the image pickup unit captures the image of the tool .
The opening / closing mechanism has a shutter that opens / closes the opening.
A machine tool in which the movement of the shutter and the movement of the lighting unit are linked . An image pickup processing unit that makes the tool image by the image pickup unit, and
A tool information storage unit that stores tool information and
A movement control unit that controls the movement mechanism,
Further prepare
The image pickup processing unit is
The imaging mode by the imaging unit includes a first imaging mode in which one tool is imaged a plurality of times and a second imaging mode in which one tool is imaged only once.
The length information in the longitudinal direction of the tool is acquired from the tool information storage unit, and either the first imaging mode or the second imaging mode is selected according to the length of the tool.
The machine tool according to claim 1, wherein when the second imaging mode is selected, the imaging unit captures the tool without the movement control unit moving the lighting unit. The machine tool according to claim 1 or 2, wherein the image pickup unit captures an image of the tool a plurality of times before and after the movement and at least one of the movement processes when the illumination unit is moved. The tool changing unit performs tool changing between the tool accommodating device and the processing device in a state where the opening is opened.
The machine tool according to any one of claims 1 to 3, wherein the image of the tool is performed by the tool accommodating device. The machine tool according to claim 2, wherein the movement control unit sets at least one of the movement presence / absence and the number of movements of the lighting unit based on the length information in the longitudinal direction of the tool. As the moving mechanism, a first moving mechanism that moves the lighting unit along the first guide rail in the longitudinal direction of the tool to be imaged, and a first moving mechanism.
A second moving mechanism that moves the image pickup unit along the second guide rail in the longitudinal direction of the tool to be imaged.
The machine tool according to any one of claims 1 to 5.

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